Back-end Packaging: Automated Inspection and Sorting

2/26/2019

Project Introduction

In manual electronics manufacturing processes that require the application of adhesives, it generally takes double the effort to complete in comparison to when automated dispensers are used. When traditional adhesive dispensers are used, the process involves using contact-type dispensers to apply adhesives to such surfaces as electronic components and LED packaging. However, with the miniaturization of products, these traditional dispensers can no longer be used. High-speed automated adhesive dispensers that provide accurate flow control as well as high-precision and contactless application are instead required for the forming of often micro- sized points, lines, and other shapes.

System Requirements

The customer required an automated adhesive dispensing system comprising pneumatic machines, image processors, I/O modules, and Internet communication control modules. Industrial computers were needed to integrate motor drivers, adhesive dispenser controllers, and high-speed cameras. The dispensing system had to maintain stable adhesive control and trajectory planning. During operation, this not only includes controlling the pneumatic cylinder but also monitoring the environmental temperature and signals from various sensors. Once dispensing is completed, the system needed to confirm that the adhesive had been applied cor rectly to the surface via machine visual inspection.

System Description

IPC-7132 being the dispenser's computation platform, it is equipped with a Core-i3 CPU, allowing precise multi-task motion control and accurate image inspection. The pneumatic components combined with PCI-1756 high speed IO card to simultaneously control the electromagnetic valve and examine signals. The PCI-1245V 4 axes DSP-Based motor control card can output its key route planning function via maximum 5Mpps impulse output equipment to the connected server motor controllers. Based on Advantech's self-developed common motion API, customers can plan customized routes by compensating linear, arc functions while controlling dispensing nozzles with PWM waves, each output volume can be determine by the timing to when the nozzles are opened and closed. Amongst them, the time required to open and close the nozzle (ON_time + Off_Time) is called a cycle. When coating adhesives, after ordering a fixed number of cycles, intricate coating patterns can be achieved by controlling the distribution via speed limitations. When coating adhesives, the adhesive’s valve and corresponding amount is decided for jetting rates of 100~200 Hz, while controlling the spacing by the nozzle's movement speed. To ensure precise multi-task motion control and accurate image inspection, an IPC-7132 chassis and AIMB-701 motherboard (Core-i3 CPU) were adopted as the industrial PC, and a PCI-1756 high-speed I/O card was installed to connect to pneumatic components in order to control the electromagnetic valves and acquire signal data. A PCI-1245 4-axis DSP-based motor control card was considered ideal for the server motor controllers because it has reserved memory for trajectory planning and a maximum pulse output of 5 Mpps. It also supports Advantech’s Common Motion API, which enables the customization of trajectories with linear and arc functions while controlling the dispensing nozzles with PWM, thereby being able to set the output volume according to the nozzle cycle (referring to the time between opening and closing the nozzle). Intricate coating patterns could thus be achieved by controlling the distribution via speed limitations. Specifically, the dispenser valve and adhesive amount could be managed at jetting speeds of 100~200 Hz and the spacing could be controlled by adjusting the nozzle’s movement speed.

System Diagram

Conclusion

The essential functions of automated inspection and sorting systems include encoder signal receiving, locating, and unit triggering.For this project, Advantech offered a comprehensive integrated software-hardware solution that satisfied the manufacturer’s usage requirements. Accordingly, the manufacturer did not incur high initial investment costs for unnecessary functions, nor have to worry that inadequate functions would render the system ineffective. Moreover,with Advantech’s technical support, the company was able to cost effectively develop an appropriate application system.

Advantech’s PCI-1784U card and custom algorithms provide practical functionality and widespread applicability for diverse manufacturing facilities. System developers with similar requirements can easily modify the parameters to employ the same example algorithms. Advantech offers integrated solutions that allow companies to maximize production efficiency by automating the inspection and sorting process.